Air cushion and seat frame

ABSTRACT

The specification discloses seat structures comprising a lightweight frame having a generally horizontal seat portion and a somewhat vertical back portion. The frame is preferably formed from metal tubing to have an inherent resiliency or springaction. Attached to the seat and back portions of the frame are inflatable cushion members formed from air impervious sheet material, such as plastic, rubberized fabric or the like. Preferably, the cushions have individual sections which are separately inflatable whereby the contour and firmness of any seat can be varied. In one embodiment, the seat and back portions of the frame have U-shaped tubular portions and the inflatable cushions have pocket-like recesses adapted to receive the Ushaped portions. In a second embodiment, the frame is formed from sheet metal, or molded from plastic and provided with a plurality of openings. The cushions include outwardly extending, resilient or deformable members spaced to correspond to openings in the frame. The members are sized slightly larger than the openings so that the cushions can be attached to the frame by deforming the members and forcing them into or through the openings.

United States Patent Briggs [451 Aug. 1,1972

[54] AIR CUSHION AND SEAT FRAME [72] Inventor: Donald L. Briggs, RD. 2,Beloit,

Ohio 44609 [22] Filed: Oct. 26, 1970 [21] Appl. No.: 83,846

[52] U.S. Cl ..297/456, 3/348, 297/DIG. 3 [51] Int. Cl. ..A47c 27/08,A470 27/18, B60n 1/06 [58] Field of Search ..297/D1G. 3, 218, 219, 229,

[56] References Cited UNITED STATES PATENTS 2,865,436 12/1958 Thorne..297/218 3,567,278 3/1971 Barecki et a1 ..297/218 3,111,344 11/1963l-loven et a1 ..297/466 X 3,515,430 6/1970 Nelson ..297/219 X FOREIGNPATENTS OR APPLICATIONS 753,936 8/1956 Great Britain ..297/456 PrimaryExaminer-Casmir A. Nunberg Attorney-Fay, Sharpe and Mulholland [5 7]ABSTRACT The specification discloses seat structures comprising alightweight frame having a generally horizontal seat portion and asomewhat vertical back portion. The frame is preferably formed frommetal tubing to have an inherent resiliency or spring-action. Attachedto the seat and back portions of the frame are inflatable cushionmembers formed from air impervious sheet material, such as plastic,rubberized fabric or the like. Preferably, the cushions have individualsections which are separately inflatable whereby the contour andfirmness of any seat can be varied. In one embodiment, the seat and backportions of the frame have U- shaped tubular portions and the inflatablecushions have pocket-like recesses adapted to receive the U- shapedportions. In a second embodiment, the frame is formed from sheet metal,or molded from plastic and provided with a plurality of openings. Thecushions include outwardly extending, resilient or deformable membersspaced to correspond to openings in the frame. The members are sizedslightly larger than the openings so that the cushions can be attachedto the frame by deforming the members and forcing them into or throughthe openings.

v5 Claims, 21 Drawing Figures PATENTEDAUB I I972 SHEET 1 BF 5 R 06 m m5V my. 0 M M 0 A 7'TORWEYS I PATENTEDAUG 1 1922 SHEET 3 OF 5 INVENTOR.DONALD L. BR/GGS m 5W 5 MM ATTORNEYS PATENTEDAus nan 3.680.918

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I ATTORNEYS AIR CUSHION AND SEAT FRAME The present invention is directedtoward the seat art and, more particularly, to an improved inflatableseat construction.

The invention is especially suited for constructing vehicle seats andwill be described with particular reference thereto; however, it will beapparent that the invention is capable of broader application and couldbe used for construction of many types of seats or chairs for a varietyof uses.

Vehicle seats currently in use generally comprise a rigid, metal framecarrying coil springs or the like and covered with suitable padding andfabric. Normally, the seats can be adjusted only a limited amount, if atall.

The general complexity of the typical vehicle seats make their costrelatively high both in terms of material cost and labor cost. Further,because of their lack of adjustability from the standpoint of positionand firmness, the seats must be designed for the average individual.Consequently, for most individuals, the seats are never as comfortableas desirable.

The present invention overcomes the above problems and provides a seatconstruction which is extremely simple and lightweight. Further, seatsconstructed in accordance with the invention can be made individuallyadjustable for firmness and position. Also, when the seats incorporatecertain aspects of the invention, contour and firmness of selectedportions of the seats can be selectively varied to suit the needs of theindividual users In accordance with the invention, the seats comprise alightweight frame having a generally horizontal seat portion and asomewhat vertical back portion. The frame is preferably, but notnecessarily, formed from metal tubing to have an inherent resiliency orspringaction. Attached to the seat and back portionsof the frame areinflatable cushion members formed from air impervious sheet material,such as plastic, rubberized fabric or the like. Preferably, the cushionshave individual sections which are separately inflatable whereby thecontour and firmness of any seat can be varied.

In accordance with a more limited aspect of the invention, the seat andback portions of the frame have U-shaped portions and the inflatablecushions have pocket-like recesses adapted to receive the U-shapedportions. With this arrangement, the cushions can be simply slipped onand off the frame.

In accordance with another somewhat limited aspect of the invention, theframe is formed from sheet metal, or molded from plastic and providedwith a plurality of openings. The cushions include outwardly extending,resilient or deformable members spaced to correspond to openings in theframe. The members are sized slightly larger than the openings so thatthe cushions can be attached to the frame by deforming the members andforcing them into or through the openings.

- A primary object of the invention is the provision of a seat structurewhich is both simple in construction and light in weight.

A further object is the provision of an inflatable seat constructionarranged so that the contour and firmness can be easily varied.

Yet another object of the invention is the provision of an improved seatassembly which uses inflatable cushions over light tubular or formedframes.

A further object is the provision of a seat of the type describedwherein the cushions can be readily disconnected from the frame.

The above and other objects and advantages will become apparent from thefollowing description when read in conjunction with the accompanyingdrawings wherein:

FIG. 1 is an exploded pictorial view of a portion of a seat formed inaccordance with the invention;

FIG. 2 is an exploded pictorial view showing the entire frame of theFIG. 1 embodiment and the back cushion of the seat;

FIG. 3 is a detailed pictorial view showing the pivotal interconnectionof the seat frame of the FIG. 1 embodiment;

FIG. 4 shows in exploded pictorial view a modified seat cushion andframe formed in accordance with the invention;

FIG. 4A illustrates in pictorial view a frame modification which can beused in the FIGS. 1 through 4 embodiments;

FIG. 5 is a modified hinge for connecting the seat and back portions ofa frame which can be used in the invention;

FIG. 6 shows an exploded pictorial view of a base or seat portion of abench-type vehicle seat embodying features of the invention;

FIG. 7 shows the back cushion and the entire seat frame of theembodiment of FIG. 6;

FIG. 8 shows in detail the method of mounting a back portion of a seatformed in accordance with the invention;

FIG. 9 shows a modified form of inflatable seat cushion which can beused in the subject invention;

FIG. 10 is a cross-section through a seat cushion formed in accordancewith the FIG. 9 embodiment illustrating the manner in which it isreceived on an associated frame;

FIG. 11 is a cross-section taken through a seat cushion formed inaccordance with further embodiments of the invention;

FIG. 12 is a pictorial view of a modified seat frame which can be usedin carrying out the invention;

FIG. 13 is a pictorial view showing the frame of the FIG. 12 embodimentand the back seat cushion and illustrating the manner in which it isconnected to the frame;

FIG. 14 illustrates the seat portion of the FIG. 12 embodiment and thecushion arrangement preferably used therewith;

FIG. 15 illustrates how upholstery or covers can be fitted to seatsformed in accordance with the invention;

FIG. 16 is a pictorial view of the bottom of a cushion illustrating anadditional manner in which the cushions can be attached to the frame;

FIG. 17 shows in pictorial view a fourth embodiment of a seat formed inaccordance with the invention;

FIG. 18 shows in exploded pictorial view how cushions can be attached tothe frame of the FIG. 17 embodiment;

FIG. 19 is'a view showing how the back cushion can be attached to thevertical portion of the frame of the FIG. 17 embodiment; and,

FIG. 20 is a detailed showing of the manner in which upholstery or seatcoverings can be applied to the cushions of the FIG. 17 embodiment.

Referring more particularly now to FIGS. 1 through 3, the overallarrangement of this embodiment of the invention can be seen as includingtubular frame assembly l comprised of a base or seat portion 12 and agenerally vertically extending back portion 14. The frame assembly cantake a variety of specific forms as will become apparent from discussionof the other embodiments of the invention; however, in the FIGS. 1though 3 embodiments, the frame assembly 10 is formed from relativelylightweight metal tubing which serves to give an inherent resiliency tothe frame. In particular, as best shown in FIGS. 1 and 3, the baseportion 12 of the frame assembly 10 comprises a single section of tubing16 formed so as to provide a pair of generally U-shaped outwardly andhorizontally extending sections 18 and 20 formed continuously with apair of base members 22 and 24. The members 22, 24 are reinforced wherethey join the horizontally extending U-shaped portions 18 and 20 bymetal bracket plates 26 and 28.which are welded or otherwise connectedto the sides. Plates 26 and 28 also provide a hinge connection for theback porfion of the seat in the manner which will subsequently bedescribed.

As can be appreciated, by forming the base of the seat from metal tubein the manner described, the seat base has a natural resiliency orspring-like action. It should be apparent that the springiness of theunit can be varied by changing the arrangement of the corner braces orusing different sizes or wall thicknesses of tubing. An additionalfeature of the tubular frame is that it can be connected with thevehicle's heating and air conditioning system for heating or cooling theframe.

Preferably, the back portion 14 of the seat frame 10 is formed ingenerally the same manner as the seat. As can best be seen in FIG. 2,the back 14 is formed from metal tube and comprises a pair of verticallyextending U-shaped portions 30 and 32 interconnected by a short bightportion 34. The inner-legs of the U-shaped portions 30, 32 have upwardlyextending sections 36 and 38 respectively. These portions are arrangedso as to provide a head cushion supporting section.

According to one feature of the invention, the cushion members for theseat portion and the generally vertical back portion are formed-as airinflatable bags which can be received over the frames. For example, asshown in FIG. 1, the cushion for the. horizontal portion of the seatassembly comprises an inflatable cushion member 40 formed from any airimpervious type of flexible sheet material such as plastic, rubberizedfabric, or the like. It should be appreciated that the particular typeof material used for forming the inflatable cushions is not ofparticular importance. Additionally, as will become-apparent hereafter,the cushion can be formed from material having a desired surfacecharacteristic or it can be formed from plain, clear sheet plastic andcovered with any type of cover. In particular, as shown in FIG. 1, thelower seat cushion 40 is formed as a sealed bag with a pair of inwardlyextending pockets or recesses 42 and 44 spaced and sized so as toreceive the U-shaped portions 18 and 20 of the base frame 16. Therecesses 42, 44 are formed from the same material as the remainingportion of the cushion and are air-tight. This allows the frarnel6 tomerely slide into the recesses and no additional sealing means arerequired between the cushion and the frame. Further, means in the formof an adjustable air valve 46 are provided to fill the cushion to adesired degree of inflation. Further, the surface of the seat can beprovided with individual air cells each individually inflatable so as toassure a desired contour. l

The cushion for the back portion of the seat is formed in generally thesame manner as the seat cushion. Note that as shown in FIG. 2, the backcushion 48 is provided with a pair of inwardly extending recesses 50, 52sized to receive the U-shaped portions 30, 32 respectively, of the backframe 14. In the FIG. 2 embodiment, the back cushion is provided withanintegral head rest portion 54 which can be separately inflatable orconnected in air flow relationship with the interior of the main portionof the cushion 48. The sections 36, 38 of the back frame 14 extendupwardly into corresponding recesses or containers positioned within thehead rest portion 54. A valve 58 is provided for deflating the backcushion to the desired degree.

It can be appreciated that the back frame 14 and the base frame 12 canbe rigidly interconnected or mounted for relative movement andadjustment. FIG. 3 shows the preferred pivotal interconnection betweenthe back frame 14 and the base frame 12. Note that pin members 35 extendthrough the lower ends of the outside legs of the back frame 14 andthrough the reinforcing plates 26, 28. Additionally, a stop block member37 is welded to the outer face of one or both of the reinforcing plates26, 28. Obviously, the stop block 37 can be made adjustable if desired.

FIG. 4 shows a modification of the manner inwhich the base cushion isconnected to the frame. Note that in the FIG. 4 embodiment, the baseframe 60 is formed with one central U-shaped portion 62 and two outer,tightly bent U-shaped portions 64 and 66. In this embodiment, the seatcushion 68 is formed generally in the manner described with reference tothe seat cushion 40 of the FIG. 1 embodiment but has only one recess oropening 70 adapted to receive the U-shaped portions 62 of the base 60.The two outer tightly bent portions 64, 66 of frame 60 are merelyreceived in inwardly extending recesses 72 and 74 which are formed inthe lower face of the cushion. In all other particulars, the cushion 68is identical to the cushion 40 of the FIG. 1 embodiment.

As is apparent, the cushions can be affixed to the frames in anyconvenient manner such as through the use of straps, releasable snaps orthe like.

FIG. 4A shows a manner in which the seat frames can be made more rigidif desired. Note that the basic tubular frame is provided with sleeveportions or members which are slipped over the ends of the formed tubesand welded or affixed thereto. These members make the frame somewhatmore rigid and can be provided with removable connections if desired.

FIGS. 5 through 7 show how the invention can be embodied in a bench-typeseat structure. In this embodiment, the base frame 90 (shown in FIG. 6)is formed substantially identical to the base frame 12 of the FIGS. 1through 4 embodiments. The primary difference is that the center portionof the frame is provided with an additional U-shaped section and acentral support bracket 92. The support brackets 92 are shown as metalangles or the like welded to the underside of the frame forming tubesand extending downwardly therefrom. The back portion of the frame 94 isalso similar to the back portion of frame of the FIG. 1 through 4embodiments. Additionally, however, the frame has a plurality ofintermediate U-shaped sections to support the back cushion entirelyalong its length. Note that the back cushion 96 is formed in the samemanner as the cushions described in the FIG. 1 through 4 embodimentsbut, in this embodiment, the back can be rigidly connected to the base90 as shown in FIG. 7. For example, a pair of pins 95 connect throughthe frame to interlock the two sections. Additionally, however, thesections can be pivotally interconnected in any convenient manner ifdesired.

An alternate approach is shown in FIG. 8. In FIG. 8, the back portion ofthe frame is rigidly mounted in the floor of the vehicle and is entirelyindependent of the base portion. As shown in FIG. 8, the ends of theframe 98 are received in openings formed in the vehicle floor. The framecan be welded in the openings or removably affixed therein.

As previously mentioned, the cushions can be formed from many types ofmaterial. Additionally, their internal structure can be varied to changetheir outer contour or to give them added strength against bulging whena particularly firm seat is desired and the internal pressure must besubstantially increased. FIG. 9 shows a cushion which can be used in theFIGS. 1 through 4 embodiments or the FIGS. 6 and 7 embodiments. Notethat the cushions shown in FIG. 9 and identified with the numeral 100are somewhat of a three ply structure including upper and lower outerfaces 102 and 104 and an intermediate partition member 106. Theinner-member 106 is connected at spaced longitudinal points by webs 108which extend from the member 106 to facing surfaces of the outer shell.Openings 110 are formed through the inner member 106 and the spacingmembers 108 to allow free flow of air through the interior of thecushion. Independent recess forming members, not illustrated in FIG. 9,connect from the outer frame receiving openings 112 to seal the interiorwhile permitting mounting of the cushion on an associated frame.

FIGS. 12 through 14 illustrate a third embodiment of the invention whichutilizes a different frame arrangement. In this embodiment, the frame isformed, for example, from stamped steel or plastic molded into theconfiguration shown. Note that the base portion 120 of the frame isprovided with a generally rectangular bottom supporting a generallyhorizontal top having indents or recesses 122 stamped or molded therein.The back portion of the frame 124 is similarly formed as a molding orstamping and has similarly shaped recesses 126. Preferably, the back ispivotally connected to the base in any convenient manner such as throughthe use of pivot pins 128 passing through generally horizontallyextending extensions 129 formed on the lower edge of the back.

The inflatable cushions are connected to the back and seat portions (124and respectively) in any convenient manner but preferably, as shown inFIGS. 13 and 14. Referring to FIG. 13, it will be seen that the cushion130 is provided with a foldable extension which connects to the upperend portion of the cushion and can be folded over the back frame 124.The foldable portion 132 can be formed from any desired material and hastabs 134 along its free edge. The tabs 134 are provided with smallopenings 136. The openings 136 are sized so as to receive resilientfingers or tabs 138 carried along the lower edge of the cushion 130. Ascan be appreciated, by positioning the cushion against the seat back 124and folding the back portion 132 downwardly, the outwardly extendingfingers or tabs 138 can be passed through the openings 136 to connectthe cushion to the frame. The tabs 138 preferably are resilient ordeformable and have a cross-section slightly greater than thecross-section of the openings 136. Thus, they are resiliently held inthe openings. Additionally, the back of the cushion 130 is molded withoutwardly extending portions 140 shaped to conform to the recesses 126formed in the back. This prevents undesired movement of the cushion onthe back while making cushion installation and removal relativelysimple.

Similarly, as shown in FIG. 14, the seat cushion is provided with amolded back or base 152 having outwardly extending portions 154 adaptedto be engaged with the molded end recesses 122 of the base 120. Theseserve to prevent movement of the cushion relative to the seat frame.Further, clip portions 156 extend from the back edge of the base 152 forengagement over the rear edge of the frame base 120.

In the FIGS. 12 through 14 embodiments, it should be appreciated thatthe inflatable portion of the seat cushions can be formed as shown inany of the preceding embodiments. Additionally, the cushions can besubdivided internally in different manners to allow any desired contourto be achieved.

As shown in FIG. 15, the seat cushions can be provided with removablefabric covers or the like. This allows the inflatable portion of thecushions to be formed from a desired material without regard to whetherit has the proper color or surface texture. Note that a fabric cover canbe slipped over the cushions and zipped in position such as illustrated.

Alternately, the cushions can be snapped over the cushion in the mannershown in FIG. 16. Note that FIG. 16 illustrates an inflatable cushionhaving a somewhat rigid bottom wall 160 provided with snaps 162. Thecover is similarly provided with snaps located so as to allow it to besnapped to the inflatable cushion.

Although not specifically mentioned, it should be appreciated that anyof the seat frames thus far described can be provided with additionaladjusting means such as guide tracks and the like. Further, theparticular seat shape and configuration can vary widely withoutdeparting from the scope of the invention.

FIG. 17 shows a further embodiment of the invention utilizing a formedor molded seat frame of the general type illustrated in FIGS. 12 through14. Specifically, the base frame has a generally rectangular bottomhousing 172 and a curved or dished top member 174. The back frame 176 issimply a dish-shaped molded or stamped metal frame part.

As shown in FIGS. 18 and 19, both the frame portions 174 and 176 areprovided with a plurality of openings 180. The openings 180 providemeans for attaching the inflatable cushions to the assembly. Note thatas shown in FIGS. 18 and 19, the cushions 182 and 184 are provided withoutwardly extending connecting members 186 which preferably areresilient and have an enlarged outer end of a size slightly larger thanthe openings 180. Preferably, the portions 186 are molded directly tothe bottom of the cushions. Altemately, there can be a separate memberattached to the cushions in any convenient manner. To install thecushions in the FIGS. 18 and 19 arrangement, the outwardly extendingportions 186 are deformed so that they may pass through the openings180. After being passed through the openings, they can be permitted toexpand into their original shape to prevent them from being withdrawnthrough the openings.

In addition to allowing the cushions to be attached to the frames, theportions 186 also allow a cover of fabric or the like to be put over thecushions. As illustrated in FIG. 20, the cushions can be covered by afabric covering 190 having flaps or tabs 192 provided with openings 194located so as to correspond to the locations of the, portions 186.

It should be understood that the particular shape of the resilientmembers 186 is not of importance and they could have any desiredcrosssection.

Referring again to the embodiments of FIGS. 1 through 11, it should benoted thatalthough a tubular frame structure is not absolutelynecessary, it is preferred for many reasons. First, the tubular framearrangement provides an inherent resiliency or springiness not presentin the FIGS. 12 through 20 embodiments. Additionally, the tubularportions of the seat frames can be connected with outside air or theoutput from the vehicle heater or air-conditioner to either cool or heatthe seat. Additionally, its simplicity makes it a simple forming matterand does not require any special stamping or molding equipment.

With all seat embodiments thus far described, it is apparent thatvarious types of trim strips and the like can be applied to thecushions, the frame, or the covers. Further, with inflatable seatcushions of the type utilized in the subject invention, the covermembers are not particularly critical as to size. For example, when thecover 190 has been applied to the cushions as shown in the FIG. 20,inflation of the cushion will cause the cover 190 to be tightlystretched to conform to the cushion. Further, if desired, the cushionscan have several internal chambers with separate air supply valves. Thisallows separate sections of the cushions to be inflated to differentlevels for contour and resilienreading and understanding of thespecification and it is my intention to include all such modificationsand alterations as part of my invention insofar as they come within thescope of the appended claims.

at is claimed is: seat structure comprising:

a generally horizontal base frame; a generally vertical back frameextending upwardly from said base frame; said base frame and said backframe being interconnected and formed from v resilient metal tubing, thetubing forming said base frame and said seat frame being bent generallybent to provide at least one generally U-shaped central portion andseparately inflatable air cushion members covering said base frame andsaid back frame and connected thereto: said air cushion members eachincluding a pocket which extends inwardly from the outer surface and issurrounded by in-flatable portions of said cushion; and, said U-shapedportions of said base frame and said back frame are received in saidpockets.

2. The seat structure as defined in claim 1 wherein said air cushionmembers each include a valve means whereby said cushion members can beinflated to a desired pressure by a user.

3. The seat structure as set forth in Claim 1 wherein said back cushionand said seat cushion are individually inflatable wherein the pressurecan be independently adjusted.

4. A seat structure comprising;

a generally horizontal base frame:

a generally vertical back frame extending upwardly from said base frame;said back frame and said base frame each including. a multiplicity ofopenings extending therethrough, separate, inflatable air cushionmembers for connection to said base frame and said back frame, each ofsaid cushion members including integral resilient connecting membersextending outwardly therefrom and positioned to correspond to theopenings in said base frame and said back frame, said connecting membershaving head portions slightly larger than said openings but deformableto pass through said openings and retain said cushions on said baseframe and said back frame.

5. The seat structure as defined in Claim 4 wherein said base frame andsaid back frame are formed of molded plastic having said openingsextending therethrough.

1. A seat structure comprising: a generally horizontal base frame; agenerally vertical back frame extending upwardly from said base frame;said base frame and said back frame being interconnected and formed fromresilient metal tubing, the tubing forming said base frame and said seatframe being bent generally bent to provide at least one generallyU-shaped central portion and separately inflatable air cushion memberscovering said base frame and said back frame and connected thereto: saidair cushion members each including a pocket which extends inwardly fromthe outer surface and is surrounded by in-flatable portions of saidcushion; and, said U-shaped portions of said base frame and said backframe are received in said pockets.
 2. The seat structure as defined inclaim 1 wherein said air cushion members each include a valve meanswhereby said cushion members can be inflated to a desired pressure by auser.
 3. The seat structure as set forth in Claim 1 wherein said backcushion and said seat cushion are indivi-dually inflatable wherein thepressure can be independently adjusted.
 4. A seat structure comprising;a generally horizontal base frame: a generally vertical back frameextending upwardly from said base frame; said back frame and said baseframe each including a multiplicity of openings extending therethrough,separate, inflatable air cushion members for connection to said baseframe and said back frame, each of said cushion members includingintegral resilient connecting members extending outwardly therefrom andpositioned to correspond to the openings in said base frame and saidback frame, said connecting members having head portions slightly largerthan said openings but deformable to pass through said openings andretain said cushions on said base frame and said back frame.
 5. The seatstructure as defined in Claim 4 wherein said base frame and said backframe are formed of molded plastic having said openings extendingtherethrough.